Shim Technology

Abstract

A shim holder includes a body having a center panel, a pair of middle panels connected to the center panel, and a pair of outer panels connected to the middle panels and adapted to be fixed to a surface to be shimmed. The body is unitary, thin, substantially flat in a normal state, and flexible. Adhesive elements are disposed on the outer panels to fix the holder to the surface to be shimmed. Also disclosed is a shim holder including an outer member; an inner member for contact with a surface to be shimmed; and at least one elastomeric connecter for connecting the outer member to the inner member. An adhesive element is disposed on the inner member for fixing the inner member to the surface to be shimmed. Further disclosed is a method of attaching a shim to a surface to be shimmed including the steps of providing a shim holder, attaching the shim holder to the surface to be shimmed, and loading at least one shim to the shim holder.

Description

BACKGROUND

1. Field

The present invention relates, generally, to building construction apparatus and methods. More particularly, the invention relates to building tools or accessories, and to methods of using such tools or accessories by carpenters or workers. Most particularly, the invention relates to a shim system, apparatus and methods. The invention is especially suitable for use in installing doors, windows and other building elements in new or existing construction.

2. Background Information

A shim is a thin and often tapered or wedged piece of material, used to fill small gaps or spaces between objects. Shims are typically used to support, adjust for better fit, or provide a level surface for doors, windows and other building elements. In carpentry or joinery, shims are typically small pieces of wood which are inserted into spaces or gaps between boards for alignment of doors, windows and the like.

An example use of shims in carpentry is in the installation of a pre-hung door. A pre-hung door is a door that is already hanging in its own frame (jambs). It is a fully self-contained unit. The main parts of a pre-hung door are door slab, hinges, and a frame. Typically, the entire unit (jambs and door) are installed at once. The unit is set it in a preformed opening and shims are used on either side of the head jamb to squeeze the unit into the opening. The hinge-side jamb is made at least level or perhaps a little higher than the strike-side jamb. Shims are inserted underneath the hinge jamb if it is not at least level. With the door open, the hinge-side jamb is shimmed until it is straight and plumb using a level and placement of shims behind the hinges. Typically, a pair of shims points in opposite directions to create a flat surface. Nails are placed through the jamb, through the shims, and into the framing. Next, the door is closed and shimming is placed under the strike-side jamb until there is an even gap between the door and the head jamb (i.e. the head jamb is level). Shims are placed behind the strike-side jamb until it is also straight and plumb. Using the door itself as a guide, shimming is placed until there is an even gap between the door and the strike-side jamb. Nails are placed through the jamb and shims and into the framing. The head jam is then shimmed and secured.

Existing shim technology is believed to have significant limitations and shortcomings. Thus, a need exists for the present invention.

All U.S. patents and patent applications, and all other published documents mentioned anywhere in this application are hereby incorporated by reference in their entirety.

BRIEF SUMMARY

The present invention provides a shim system, apparatus, article and methods which are practical, reliable, accurate and efficient, and which are believed to fulfill a need and to constitute an improvement over the background technology.

In one aspect, the invention provides a shim holder including a body having a center panel, a pair of middle panels connected to the center panel, and a pair of outer panels connected to the middle panels and adapted to be fixed to a surface to be shimmed. The body is unitary, thin, substantially flat in a normal state, and flexible. Adhesive elements are disposed on the outer panels to fix the holder to the surface to be shimmed.

In another aspect, the invention provides shim holder including an outer member; an inner member for contact with a surface to be shimmed; and at least one elastomeric connecter for connecting the outer member to the inner member. An adhesive element is disposed on the inner member for fixing the inner member to the surface to be shimmed.

In a further aspect, the invention provides method of attaching a shim to a surface to be shimmed including the steps of providing a shim holder, attaching the shim holder to the surface to be shimmed, and loading at least one shim to the shim holder.

The aspects, features, advantages, benefits and objects of the invention will become clear to those skilled in the art by reference to the following description, claims and drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

The present invention, and the manner and process of making and using it, will be better understood by those skilled in the art by reference to the following drawings.

FIG. 1 is a front view of an embodiment of a shim holder of the present invention.

FIG. 2 is a front view of another embodiment of the shim holder.

FIG. 3A illustrates an embodiment of a method of using a shim holder, of the present invention.

FIG. 3B is a flow chart of an embodiment of the method of using a shim holder.

FIG. 4 is a front view of yet another embodiment of the shim holder of the present invention.

FIG. 5 is a back view of the shim holder shown in FIG. 4.

FIG. 6 is a side view of the shim holder.

FIG. 7 is a front view of the shim holder.

FIG. 8 is a back view of the shim holder.

FIG. 9 is a perspective view of the shim holder.

FIG. 10 is a front view of the shim holder with a shim deployed in the holder.

FIG. 11 is a perspective view from the back of the shim holder with a pair of shims deployed therein.

FIG. 12 is a perspective view from the front of the shim holder.

FIG. 13 is a side view of the shim holder.

FIG. 14 is a front view of still another embodiment of the shim holder of the present invention.

FIG. 15 is a front view of the shim holder of FIG. 14, with a pair of shims inserted therein.

FIG. 16 is a back view of the shim holder.

FIG. 17 is a side view of the shim holder.

FIG. 18 is a front view of still another embodiment of the shim holder of the present invention.

FIG. 19 is a back view of the shim holder of FIG. 18 with a shim inserted therein.

FIG. 20 is a front view of a further embodiment of the shim holder of the present invention.

FIG. 21 is a perspective view of the shim holder of FIG. 20.

FIG. 22 is a further perspective view of the shim holder.

FIG. 23 is a front view of still a further embodiment of the shim holder of the present invention.

FIG. 24 is a perspective view of the shim holder of FIG. 23 with a shim inserted therein.

FIG. 25 is a front view of yet a further embodiment of the shim holder of the present invention, with a shim inserted therein.

FIG. 26 is a perspective view of the shim holder of FIG. 25, again with a shim inserted therein.

FIG. 27 is a front view of yet another embodiment of the shim holder of the present invention, with a shim inserted therein.

FIG. 28 is a perspective view of still another embodiment of the shim holder of the present invention, with a shim inserted therein.

FIG. 29 is a front view of yet another embodiment of the shim holder of the present invention, with a shim inserted therein.

FIG. 30 is a perspective view of the shim holder of FIG. 29, again with a shim inserted therein.

FIGS. 31-34 illustrate an alternative embodiment of the shim and shimming technology of the present invention, involving an adjustable wedge system.

FIGS. 35 and 36 another alternative embodiment of the shim system of the present invention.

FIG. 37 illustrates still another alternative embodiment of the shim system of the present invention.

FIGS. 38 and 39 illustrate yet another alternative embodiment of the shim system of the present invention

FIG. 40 illustrates a further alternative embodiment of the shim system of the present invention

DETAILED DESCRIPTION

The installation of doors, windows and other such building elements or features, involves placing the element into a rough opening in the construction. The construction may be new or remodel and it may be residential, commercial or industrial. After placement, the element must be oriented so that it is plumb, level and square. This almost universally involves adjustment and securement by using shims, typically wedge shaped wooden shims. The shims are placed between the rough opening framing member (i.e. stud) and the frame (i.e. jamb) of the element.

The present invention provides a technology for improving the shimming process by way of a holder for such shims or, in some embodiments, an adjustable shim assembly.

FIG. 1 shows an embodiment of a shim holder 10 of the present invention. The shim holder 10 has a body which is unitary and preferably thin, substantially flat in a normal state, and flexible. The body is preferably constructed of a flexible plastic material.

The body 10 includes a center panel or region 11, a pair of middle panels 12a and b, and a pair of outer or end panels 13a and b. The middle panels 12 are separated from the center panel 11 by slots or channels 20a and b in the side (relative to the drawing in FIG. 1). Channels 20a and 20a′ (prime) are preferably aligned with each other and extend equidistantly from the sides, as do the channels 20b and 20b′. Regions or area 21a and b between the slots 20 couple the center panel 11 to the middle panels 12. The outer or end panels 13 are separated from their respective middle panels 11 by slots or channels 25a and b in the side (relative to the drawing in FIG. 1). Regions or area 26a and b between the slots 25 couple the center panel 11 to the middle panels 12. Slots 25 are also preferably aligned and of equivalent dimensions. Slots or channels 30a and b are preferably disposed in middle panels 12a and b respectively. The slots 25 are preferably centered in the panels 12.

The side of the body shown in FIG. 1 has adhesive members 13a and b disposed on the outer panels 13a and b respectively. The opposite side of the body (not shown) may optionally have one or more adhesive members.

The body 10 and panels 11-13 are shown to have rectangular configurations with substantially rectilinear (straight line) peripheral edges and radiused corners. In the embodiment shown, preferred dimensions are as follows. Other dimensions may be used by those skilled in the art and are within the purview of the invention.

	“A”	1½	inches (in.)
		(2.0	cm.)
	B	⅞	in.
	C	10/16	in.
	D	1/16	in.
	E	1/16	in.
	F	1⅛	in.
	G	2¼	in
	H	3⅜	in.
	I	9/16	in.
	J	9/16	in.
	K	R ⅛	in.
	L	R 1/32	in.
	M	¾	in.
	N	¾	in.
	X	4½	in.
	Y	4½	in.

FIG. 2 is a front view of another embodiment of the shim holder 100. It is constructed and arranged substantially similar to the shim holder 10 of FIG. 1, comprising a body with a center panel 110, middle panels 111a and b, and outer panels 112a and b. By way of illustrating alternative, non-limiting, structural dimensions, those for shim holder 100 are as follows.

	“O”	4⅜	inches (in.)
	P	4⅜	in.
	Q	1½	in.
	R	1 17/32	in.
	S	13/16	in.
	T	⅝	in.
	U	5/16	in
	V	5/16	in.
	W	1 5/16	in.
	W′ (Prime)	9/16	in.

FIGS. 3A and B illustrates an embodiment of a method 200 of using a shim holder, of the present invention, to install a building element, for example a door 210, in a structure, for example a wall 215. The first step 230 involves selecting a shim holder for example shim holder 10 describe above. The second step of this embodiment of the method involves activating 231 shim holder 10a by removing release liners 35 to expose adhesive 34 of elements 13a and b. The shim holder 10a is then oriented and placed 232 at a predetermined position on the jamb 220 of the door 210. The next step of the process 200 involves loading 233 the holder 10 with one or more shims 225. One shim 225a is aligned with insertion edge 226a and moved between the holder body 10 and the jamb 220. The body 10 flexes to create an insertion pocket 227 that accommodates all of the shim 225a that is inserted by the user. A further shim 225b may be inserted, wholly or partly, in the opposite direction beginning at edge 226b. Still further shims or portions of shims may be inserted by the user as necessary or desired leveling.

The process 200 is repeatable for additional shim holders 10b, 10c, 10d and the like at further positions on the jamb 200 as desired by the user. The shims 225 may be adjusted and trimmed as necessary during leveling and door 210 installation. The door 210 may be secured, for example by inserting nails or other fasteners (not shown) through the holders 10 and shims 225 and into the jambs 220. Shimming may be used on one or both vertical jambs or the horizontal jamb.

FIGS. 4-13 disclose yet another embodiment of the shim holder 300 of the present invention. The holder 300 comprises first (outer) and second (inner) members 315a and 315b respectively, and elastomeric ties 317 (preferably rubber or polymeric bands). An adhesive element (including adhesive strip 319 and release liner 320) is disposed on the outer surface of inner member 315b, for connection to a jamb.

The members 315 are constructed of a polymeric material and have predetermined configurations as shown. In the embodiment shown, preferred (but non-limiting) dimensions are as set forth below:

	“X”	5¼	inches (in.)
	Y	2	in.
	A	3¼	in.
	B	1	in.
	C	1/16	in.
	D	⅛	in.
	E	¼	in
	F	¼	in.

The inner and outer members 315 each preferably have a center region 325 and end regions 326 which are flexible with respect to the center region 325 to facilitate insertion of shims 330 at the ends.

The shim holder 300 is deployed by adhesively connecting it to a jamb and inserting one or more shims 330 between the members 315 as shown in FIG. 6.

FIGS. 14-17 show of still another embodiment of the shim holder 400 of the present invention. The shim holder 400 is constructed of a flexible, preferably polymeric material and has a thin, flat, substantially sheet-like, configuration as shown. The body 400 has slot array 401 of a predetermined configuration. An adhesive connector 402 is disposed on one side of the body 400, preferably centrally.

In use, the holder 400 is connected to a jamb via the connector 402, and one or more shims 403 are inserted as shown into the array 401 to form, by way of the combination of the array 401 design and flexible body, an insertion and holding passage 404.

FIGS. 18 and 19 disclose still another embodiment of the shim holder 500 of the present invention. The shim holder 500 is also constructed of a flexible material and has a thin, flat, substantially sheet-like, configuration as shown. The body 500 also has slot array 501 of an alternative, predetermined configuration. An adhesive connector (not shown) is disposed on one side of the body 500, preferably centrally.

In use, the holder 500 is connected to a jamb and one or more shims 502 are inserted as shown into the array 501 to form, by way of the combination of the array 501 design and flexible body, an insertion and holding passage 503.

FIGS. 20-22 show a further embodiment of the shim holder 600 of the present invention. The holder 600 comprises first (outer) and second (inner) members 601a and 601b respectively, and elastomeric ties 603 (preferably rubber or polymeric bands). An adhesive element (not shown) is disposed on the outer surface of inner member 601b, for connection to a jamb. The members 601 are constructed of a polymeric material and have predetermined configurations as shown. In use, the shim holder 600 is deployed by adhesively connecting it to a jamb and inserting one or more shims 603 between the members 601a and b.

FIGS. 23 and 24 disclose still a further embodiment of the shim holder 700 of the present invention. The holder 700 comprises coupled, first (outer) and second (inner) members 701a and 701b respectively. An adhesive element (not shown) is disposed on the outer surface of inner member 701b, for connection to a jamb. The members 701 are constructed of a polymeric material and have predetermined configurations as shown. In use, the shim holder 700 is deployed by adhesively connecting it to a jamb and inserting one or more shims 702 between the members 701a and b to thereby form a flexible insertion and holding passage 703.

FIGS. 25 and 26 show yet a further embodiment of the shim holder 800 of the present invention, with a shim inserted therein. The holder 800 comprises coupled, first (outer) and second (inner) members 801a and 801b respectively. An adhesive element (not shown) is disposed on the outer surface of inner member 801b, for connection to a jamb. The members 801 are constructed of a flexible material and have predetermined configurations as shown. In use, the shim holder 800 is deployed by adhesively connecting it to a jamb and inserting one or more shims 802 between the members 801a and b to thereby form a flexible insertion and holding passage 803.

FIG. 27 discloses yet another embodiment of the shim holder 900 of the present invention, with a shim 902 inserted therein. The holder 900 comprises first (outer) and second (inner) members 901a and 901b respectively, which are coupled by connectors 904. An adhesive element (not shown) is disposed on the outer surface of inner member 901b, for connection to a jamb. The members 901 are constructed of a flexible material and have predetermined configurations as shown. In use, the shim holder 900 is deployed by adhesively connecting it to a jamb and inserting one or more shims 902 between the members 901a and b to thereby form a flexible insertion and holding passage 903.

FIG. 28 show still another embodiment of the shim holder 1000 of the present invention, with a shim 1002 inserted therein. The holder 1000 comprises first (outer) and second (inner) members 1001a and 1001b respectively, which are coupled by connector 1004. An adhesive element (not shown) is disposed on the outer surface of inner member 1001b, for connection to a jamb. The members 1001 are constructed of a flexible material and have predetermined configurations as shown. In use, the shim holder 1000 is deployed by adhesively connecting it to a jamb and inserting one or more shims 1002 between the members 1001a and b to thereby form a flexible insertion and holding passage 1003.

FIGS. 29 and 30 disclose yet another embodiment of the shim holder 1100 of the present invention, with a shim 1102 inserted therein. The holder 1100 comprises first (outer) and second (inner) members 1101a and 1101b respectively, and elastomeric ties 1103 (preferably rubber or polymeric bands). An adhesive element (not shown) is disposed on the outer surface of inner member 1101b, for connection to a jamb. The members 1101 are constructed of a flexible material and have predetermined configurations as shown. The shim holder 1100 is deployed by adhesively connecting it to a jamb and inserting one or more shims 1102 between the members 1101.

FIGS. 31-34, 35-36, 37, 38-39 and 40 show alternative embodiments 1200, 1300, 1400, 1500 and 1600 respectively of the shim and shimming technology of the present invention, involving an adjustable wedge system. These arrangements involve shim or wedge elements which are coupled together and adjustable via a mechanical adjustment element, for example a screw element (preferably a tapered screw), so that the shims spread apart or move closer. The arrangements are connectable to a frame or jamb, for example via an adhesive so that they attach quickly, stay in place, and may be used in a stacking or other combination. The arrangements may be constructed of a durable, light weight material such as plastic. Such material is resistant to deterioration and mold. They provide an adjustable, stable and self aligning unit that is easy, fast and accurate to use.

Although the embodiments of the apparatus and methods of the invention are described in terms of up, down, vertical, horizontal, transverse (lateral), longitudinal, and the like, it should be understood that variations from the absolute vertical, horizontal, transverse, and longitudinal are also within the scope of the present invention.

Although the apparatus/method has been described in connection with the field of carpentry, it can readily be appreciated that it is not limited solely to such field, and can be used in other fields.

The embodiments above are chosen, described and illustrated so that persons skilled in the art will be able to understand the invention and the manner and process of making and using it. The descriptions and the accompanying drawings should be interpreted in the illustrative and not the exhaustive or limited sense. The invention is not intended to be limited to the exact forms disclosed. While the application attempts to disclose all of the embodiments of the invention that are reasonably foreseeable, there may be unforeseeable insubstantial modifications that remain as equivalents. It should be understood by persons skilled in the art that there may be other embodiments than those disclosed which fall within the scope of the invention as defined by the claims. Where a claim, if any, is expressed as a means or step for performing a specified function it is intended that such claim be construed to cover the corresponding structure, material, or acts described in the specification and equivalents thereof, including both structural equivalents and equivalent structures, material-based equivalents and equivalent materials, and act-based equivalents and equivalent acts.

Claims

1. A shim holder comprising a body having a center panel, a pair of middle panels connected to the center panel, and a pair of outer panels connected to the middle panels and adapted to be fixed to a surface to be shimmed.

2. The shim holder of claim 1, wherein the body is unitary, thin, substantially flat in a normal state, and flexible.

3. The shim holder of claim 1, wherein the body is constructed of a flexible plastic material.

4. The shim holder of claim 1, wherein the middle panels are separated from the center panel by at least one slot.

5. The shim holder of claim 4, wherein the outer or end panels are separated from their respective middle panels by at least one slot.

6. The shim holder of claim 1, further comprising an adhesive member disposed on each outer panel.

7. The shim holder of claim 1, wherein the body has substantially rectangular configuration with a predetermined size for connection to a surface to be shimmed.

8. The shim holder of claim 1 being used by a method comprising the steps of providing a shim holder, adhering the shim holder to a surface to be shimmed, and loading the shim holder with at least one shim.

9. A shim holder comprising an outer member; an inner member for contact with a surface to be shimmed; and at least one elastomeric connecter for connecting the outer member to the inner member.

10. The shim holder of claim 9 further adhesive element disposed on the inner member for fixing the inner member to the surface to be shimmed.

11. The shim holder of claim 10, wherein the elastomeric member is a rubber band.

12. The shim holder of claim 10, wherein the inner and outer members are constructed of a polymeric material.

13. The shim holder of claim 12, wherein the center of the inner and outer members is substantially rigid, and the ends of the inner and outer members are relatively flexible.

14. The shim holder of claim 9, being used by a method comprising the steps of providing a shim holder, adhering the shim holder to a surface to be shimmed, and loading the shim holder with at least one shim.

15. A method of attaching a shim to a surface to be shimmed comprising the steps of providing a shim holder, attaching the shim holder to the surface to be shimmed, and loading at least one shim to the shim holder.